High-Binder Lignocellulosic Sheet Material for Dimensional Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sheet-like materials, such as laminate flooring and wood-plastic composites, face issues with dimensional stability due to water absorption, leading to swelling and unsightly joints, while alternatives like stone plastic composites and polyvinyl chloride are environmentally unsound.
Innovation Solution
A sheet-shaped material composed of fibers and a binder, where the binder content exceeds 50% by weight, using lignocellulosic, organic, or inorganic fibers, and a non-swelling binder like melamine, with optional elasticizing additives, is produced through a process involving binder application and pressing, avoiding extrusion and kneading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If wood fibers are used in sheet-like materials, then the material is inexpensive and renewable, but the material swells when exposed to water or humidity
Solution Approach 1:
The invention changes the key parameter of binder content from conventional levels (typically 5-15% in HDF) to a majority composition (>50% by weight). This parameter change transforms the material's response to moisture, as the high binder content creates a matrix that prevents fiber swelling while maintaining the renewable fiber component.
Solution Approach 2:
The invention creates a composite material where binder and fibers form a new material system with properties different from the individual components. The binder acts as a hydrophobic matrix that protects the hygroscopic fibers from water absorption, combining the advantages of renewable fibers with the dimensional stability of synthetic binders.
2Stability of the object's composition
If binder content is increased to reduce swelling, then dimensional stability improves, but the proportion of renewable fiber content decreases
Solution Approach 1:
The invention changes the threshold parameter of binder content from conventional levels to majority composition (>50% by weight). This parameter change allows the material to achieve dimensional stability while still incorporating significant amounts of renewable fibers, as the binder acts as a protective matrix rather than a mere binding agent.
3Stability of the object's composition
If conventional extrusion processes are used for WPC, then dimensional stability is achieved, but production equipment is not suitable for larger sheet dimensions
Solution Approach 1:
The invention replaces the extrusion process with a pressing process. Instead of forcing material through a die under high shear (extrusion), the material is formed by applying pressure between plates or rollers (pressing). This substitution allows for production of large sheet dimensions using conventional wood-based panel equipment while maintaining dimensional stability through the high binder content formulation.
4Stability of the object's composition
If alternative materials like SPC or PVC are used to eliminate swelling, then dimensional stability improves, but environmental soundness deteriorates due to halogens and terephthalates
Solution Approach 1:
The invention applies local quality by using different binder types in different layers or regions of the material. The binder system is designed to provide dimensional stability where needed while using environmentally benign components, avoiding the widespread use of harmful substances like halogens and terephthalates found in conventional SPC and PVC products.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The material exhibits minimal swelling, high strength, and dimensional stability, allowing for versatile applications in construction and furniture, while being environmentally friendly and produced on existing manufacturing equipment.
Implementation Method 1
For hygroscopic fibers that can absorb moisture (e.g., lignocellulosic fibers), the fiber content is specified as fibers dried to constant weight
Implementation Method 2
pressing the fiber cake in a press while the binder hardens to produce a sheet-shaped material
Implementation Method 3
This coating hardens under pressure and temperature, forming a firmly bonded laminate
Data Source
Figure 1
AI summary
The invention relates to planar material comprising lignocellulose fibres and binding agents. According to the invention, in order to provide planar material using fibres having reduced swelling, one part of the binding agent has more that 50 wt.% of the planar material. The invention further relates to a method for producing the planar material according to the invention.